BCBL Troubleshooting Knowledge Base (Complete)

Resolution Check: Remote operates after charge/reprogram?

Escalation: If unresolved: Warranty check → replace RC/FOB; create ticket.

Notes: Solar cannot recover from >50% depletion—booster charge required.

Resolution Check: Battery holds charge for a week of normal use?

Escalation: If not: load/capacity test; replace battery/charger.

Notes: Target ≥500 CCA and ~160Ah reserve (model dependent).

Steps: Low battery behavior. Fully charge with 10A; re-program FOB if needed.

Resolution Check: Runs normally after full charge?

Escalation: If not: escalate electrical diagnostics.

Steps: Clean/tighten cables/terminals; check for corrosion/undersized wire; load test battery.

Resolution Check: Terminals cool after fix under load?

Escalation: If not: replace failing battery; inspect connections.

Steps: Replace FOB battery; hold transmitter higher; reduce EMI (power lines/towers).

Resolution Check: Range acceptable now?

Escalation: If not: inspect receiver/antenna; relocate powerpack if needed.

Steps: Initial overflow can occur after first full-down. Purge air, set level 1–2″ from top with lift down; inspect/tighten fittings.

Resolution Check: Level stable / no overflow?

Escalation: If not: service seals/fittings; check for overfill.

Resolution Check: Root cause isolated?

Escalation: If unresolved: service pump or cylinder accordingly.

Steps: Undo/redo the four hydraulic QDs inside powerpack; ensure fully seated; check lock/check valve function.

Resolution Check: Movement restored?

Escalation: If not: valve/lock failure; escalate.

Steps: With lift down, reservoir 1–2″ from top; fully charge battery; confirm boat weight within lift capacity; check relief setting.

Resolution Check: Reaches full up under load?

Escalation: If not: verify pressure vs spec; escalate.

Steps: Perform FL6 Orifice Swap to correct side-to-side down-speed variance; verify QDs, flow-control orifices and down valves are clean/operational.

Resolution Check: Equalized descent after swap?

Escalation: If not: inspect down valves and orifices; escalate.

Notes: Service ref: FL6 Orifice Swap bulletin.

Resolution Check: Holds charge after maintenance and booster?

Escalation: If not: replace battery; counsel on solar limits.

Notes: All lifts use one battery except FL10/FL13/SL18/SL24 use two.

Resolution Check: Recovery improved?

Escalation: If not: test battery/charger; inspect fuses/wiring.

Resolution Check: Motor runs normally after corrections?

Escalation: If not: check for water intrusion; replace affected components.

Resolution Check: Bidirectional motion restored?

Escalation: If not: check coil power/ground; escalate.

Resolution Check: Full motion restored after seating?

Escalation: If not: inspect QD internals and hoses; replace as needed.

Resolution Check: Stable operation after remediation?

Escalation: If not: replace affected components proactively.

Resolution Check: Fob operates after program/battery?

Escalation: If not: replace RC under warranty; create ticket.

Resolution Check: Outputs present and motor runs?

Escalation: If outputs missing: repair RC wiring/fuse; replace RC if failed.

Steps: UP/DOWN switch likely broken or lead off; replace switch or full RC assembly if preferred.

Resolution Check: Manual switch restored?

Escalation: If not: replace RC assembly.

Steps: RC box power ON; battery >12.5V; wires to solenoids tight/corrosion-free.

Resolution Check: Operates via manual after fixes?

Escalation: If not: solenoid/RC power path diagnostics.

Steps: Confirm manual switch works; re-program FOB; replace FOB battery.

Resolution Check: Fob runs lift now?

Escalation: If not: RC receiver diagnostics / replacement.

Steps: Replace FOB battery; move position/height; reduce EMI sources.

Resolution Check: Range acceptable?

Escalation: If not: inspect antenna/receiver.

Steps: Verify charger/solar connections; ensure solar in direct sun; booster charge if <50% SOC.

Resolution Check: Holds charge after cycle?

Escalation: If not: test charger and battery; replace as needed.

Steps: Depressurize via RC box; wrench on QDs; clear debris from threads.

Resolution Check: QDs connect smoothly?

Escalation: If not: replace damaged fittings/QDs.

Steps: New install air purge may burp fluid; set level after purge; tighten leaking fittings/gaskets.

Resolution Check: Dry after retest?

Escalation: If not: service seals/fittings.

Steps: Clean/tighten terminals; load test battery; inspect wiring gauge/resistance.

Resolution Check: No abnormal heat?

Escalation: If not: replace battery; inspect cable ends.

Steps: Verify RC power is ON; check battery voltage.

Resolution Check: Operates via manual?

Escalation: If not: pump power/solenoid diagnostics.

Steps: Confirm manual works; re-program fob; replace fob battery.

Resolution Check: Fob works after steps?

Escalation: If not: RC receiver diagnostics.

Steps: Increase pump relief 1/4 turn (~250 psi); ensure fluid above intake; verify SQBB valve reaches ~3350 psi and replace if required.

Resolution Check: Cover actuates fully?

Escalation: If not: escalate valve/pressure testing.

Steps: Verify system pressure and sequencing valve function; adjust per manual.

Resolution Check: Holds until fully uncovered?

Escalation: If not: escalate.

Steps: Initial burp possible; after purge, reset level and check for leaks; tighten fittings/gaskets.

Resolution Check: Dry after retest?

Escalation: If not: service seals/fittings.

Steps: Clean/tighten terminals/cables; load-test battery.

Resolution Check: No abnormal heat after fix?

Escalation: If not: replace battery; inspect resistance path.

Steps: Torque roller per manual; ensure cover not catching fin plates; add Wind Guide accessory if needed.

Resolution Check: Smooth operation restored?

Escalation: If not: escalate.

Steps: Verify roller torque; adjust bow guide ropes (3E); add elastic cord (3F).

Resolution Check: Catches bow consistently?

Escalation: If not: escalate.

Steps: Adjust bow guide ropes per 3E; widen spreader bar if necessary.

Resolution Check: Pops over shoulders?

Escalation: If not: escalate.

Resolution Check: Operates after checks?

Escalation: If not: escalate to technician.

Steps: Use ASC limit-switch bypass plug to test. CAUTION: do not run to hard stops. If both directions work with bypass, replace/adjust limit switches.

Resolution Check: Both directions with bypass?

Escalation: If not: motor/control path issue—escalate.

Resolution Check: Moves after checks?

Escalation: If not: limit switch/ASC/winch diagnostics.

Steps: Use 1‑1/8″ socket or Floe Speed Wrench; CW lowers / CCW raises; alternate wheel‑kit legs to reduce binding; drill in clutch mode; do not force at end‑travel.

Resolution Check: Level achieved?

Escalation: If not: inspect leg threads/wheel kit; escalate.

Steps: If wheels sunk, slowly rock/pull; use winch/vehicle with steady pull (no jerking). Use helpers; consider airtight wheels for mud.

Resolution Check: Dock freed?

Escalation: If not: schedule service.

Steps: Square frame; adjust front/rear bow tension; re‑lace/retension fabric; inspect for stretched fabric/wind damage; secure hardware.

Resolution Check: Fabric taut and shedding water?

Escalation: If not: replace fabric or bent bows; order parts.

Steps: Loosen, square side frames, equalize spacing; seat cross members; align then retighten; check for bent tubes.

Resolution Check: Frame square & secure?

Escalation: If not: replace damaged components.

Steps: Verify pivoting tail alignment; roller configuration matches hull strakes; mounts correct (Slide vs Duraflexx). Adjust roller spacing/tail angle; retest.

Resolution Check: Loads/rolls off smoothly?

Escalation: If not: adjust mounts; inspect rollers for wear.

Steps: Battery >12.5V; connections tight; check starter‑solenoid trip while pressing Up/Down; inspect limit/stop wiring/connectors; verify valve coil power.

Resolution Check: Operates after electrical checks?

Escalation: If not: replace faulty solenoid/valve; escalate.

Steps: Listen for Up/Down valve clicks; swap suspect valve/coil; verify QDs are tight; inspect controller output for Up vs Down.

Resolution Check: Both directions restored?

Escalation: If not: replace failed coil/valve; escalate.

Steps: Inspect PO check valve; swap #1/#2 and test if drift follows; check hoses/fittings for leaks.

Resolution Check: Holds position after repair?

Escalation: If not: cylinder blow‑by test; replace seals/cylinder.

Steps: LED ON? Confirm GFI circuit. Wiring: red→+, black→−. With charger connected battery should read >13V; unplug and compare. Replace charger if no change.

Resolution Check: Maintains charge with known‑good charger?

Escalation: If not: replace charger or battery.

Steps: Cap beams square/lagged; crossbeams seated on stop blocks; cables routed/tensioned (fine adjust blocks); check hydraulics/electrical; purge air; run setup.

Resolution Check: Even movement after retest?

Escalation: If not: rotary motor/valve diagnostics; escalate.

Steps: Install counterweights in catwalk ends (motor side); maintain tension when lowering; supervise first water cycle; re‑tension cables.

Resolution Check: No unspooling after counterweights?

Escalation: If not: reroute/re‑tension; inspect pulleys/guards.